Expert 2007, 2.0 HDI, not starting after engine swap

[reinis_me]

Hi!

We have a Peugeot Expert 2007 with a DW10UTED4 / RHK engine and a Siemens VDO ECU SID803A. VIN: VF3**************[VIN obfuscated, can be read by forum staff].

An engine swap was performed. Only the block and the head were replaced; all the electrics, fuel system (except the pump), and other components were retained from the original engine. The reason for the swap was a failed injection pump and a broken camshaft.

Now, the engine doesn’t start at all.

What we have:

No fault codes
Fuel rail pressure ~300 bar
Camshaft/crankshaft synchronization OK
RPM while cranking stable at ~250 rpm
Coolant temperature = ambient


We also tried to start it by towing – no luck. There is no smoke, and it tends to start only with gas.

Both I and the guys at the service are getting quite desperate. What makes this situation more challenging is that the car is located in the Latvian countryside, so access to more specialized diagnostic tools is limited.

Thanks in advance!

[mickthemaverick]

I would check all the pipework for vacuum leaks as a next move

[PaulC5]

Is the immobiliser recognising the key - put it in the ignition switch and open the driver's door - if recognised usually a warning will be given.

[Steve Walsh]

As Paul says, check key. If it fires with a snort of gas you have a No fuel injection problem

[mickthemaverick]

Am I losing it? As the engine is cranking I thought that means the ecu is happy with the key? No?

[reinis_me]

Hi! Thanks for the replies.

Nope, there is no wanring beep with the key in place and doors open. Also a guy in another forum recommended to wait for two minutes with ignition on for some stuff with BSI to happen but that also didn't change anything.

Here are some new observations that something has gone really bad.

- Both front and rear marker lights turn on when the ignition is on (switch is off).
- After about 20 seconds with the ignition on, the small LCD in the dashboard and the fuel and temperature gauges switch off.
- Immediately after the battery is connected, the power windows, radio, wipers, and probably other equipment work, but after a minute or two all of this stops working until the next time we disconnect and reconnect the battery.
- There is no warning signal when the key is in the ignition and the driver’s door is open.
- After connecting the battery, the wipers sometimes switch on by themselves (switch is off) when something else is turned on (like the power windows).



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Am I losing it? As the engine is cranking I thought that means the ecu is happy with the key? No?

I don't think so. I also have 2002 Partner which has two keys and only one has that immo chip or whatever and it cranks the same with both keys, just doesn't start.

[reinis_me]

So.. what we have at the moment.

I understood that car enters economy mode after standing 20..30s in ignition. As I understand from other threads, the correct timing of this should be about 30 minutes not seconds so we may have a power leak.

Also I now know that the "beep test" fails, however I don't know, maybe the economy mode cancels the door beep too?

In other news, can someone explain me, what's this? That small patch wire doesn't look OEM, also the contacts look a bit green.

[myglaren]

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